U.S. patent application number 10/156560 was filed with the patent office on 2003-11-27 for base pan and cabinet for an air conditioner.
Invention is credited to Balderrama, Jose L., Beaver, Danny D., Burleson, Douglas S., Field, Jay E., Hudgens, Benjamin F., Jung, Hans J., Kilgo, Richard S., Norrell, Billy W., Stewart, Jeffrey L., Wendt, Michael E..
Application Number | 20030217563 10/156560 |
Document ID | / |
Family ID | 29549218 |
Filed Date | 2003-11-27 |
United States Patent
Application |
20030217563 |
Kind Code |
A1 |
Wendt, Michael E. ; et
al. |
November 27, 2003 |
BASE PAN AND CABINET FOR AN AIR CONDITIONER
Abstract
An air conditioner includes an outdoor section comprising an
outdoor coil, a fan, and a refrigerant compressor housed within a
cabinet. The cabinet includes an outer wrapper supported by a
plastic base. The base and wrapper include features that facilitate
the cabinet's assembly and shipping, enhance its appearance, and
ensure its functional and structural integrity. For example, the
base includes breakaway shipping tabs, lead-ins that help guide the
wrapper and coil into position during assembly, and snaps that help
hold the wrapper in place with a minimal number of screws. The
wrapper includes watertight screw-receiving dimples for mounting
electrical hardware, side panels that interconnect by way of a
novel vertically sliding fit, and a spacer for protecting the coil
from being crushed by the wrapper. A frame that supports the fan
also supports the cabinet's top cover.
Inventors: |
Wendt, Michael E.;
(Chandler, TX) ; Hudgens, Benjamin F.; (Van,
TX) ; Jung, Hans J.; (Chandler, TX) ;
Burleson, Douglas S.; (Lindale, TX) ; Norrell, Billy
W.; (Panama City Beach, FL) ; Stewart, Jeffrey
L.; (Whitehouse, TX) ; Kilgo, Richard S.;
(Whitehouse, TX) ; Balderrama, Jose L.; (Tyler,
TX) ; Field, Jay E.; (Troup, TX) ; Beaver,
Danny D.; (Tyler, TX) |
Correspondence
Address: |
William J. Beres - 12-1
Trane
3600 Pammel Creek Road
La Crosse
WI
54601
US
|
Family ID: |
29549218 |
Appl. No.: |
10/156560 |
Filed: |
May 24, 2002 |
Current U.S.
Class: |
62/298 ;
62/507 |
Current CPC
Class: |
F24F 2013/207 20130101;
F24F 1/18 20130101; F24F 1/56 20130101; F28F 9/00 20130101; F24F
1/38 20130101; F24F 1/46 20130101; F25B 39/04 20130101; Y10T
29/49876 20150115; F24F 1/58 20130101; Y10T 29/49826 20150115; F24F
1/50 20130101 |
Class at
Publication: |
62/298 ;
62/507 |
International
Class: |
F25D 019/00; F25B
039/04 |
Claims
1. An outdoor section for an air conditioner, comprising: a base; a
wrapper, said wrapper extending vertically upward from said base to
form an enclosure and including a plurality of side panels
supported by said base and a plurality of corner panels supported
by said base, at least one of said panels and at least one of said
corner panels being engaged in a vertically sliding fit, said
vertically sliding fit allowing for relative vertical sliding
movement between said at least one of said side panels and said at
least one of said corner panels but preventing horizontal
separation therebetween; a heat exchanger coil, said heat exchanger
coil being disposed internal of said wrapper and disposed on said
base; a top cover, said top cover overlying said wrapper and having
at least one opening.
2. The outdoor section of claim 1 wherein said at least one side
panel has a first edge and said at least one corner panel as a
mating edge, said first edge engaging said mating edge in said
vertically sliding fit.
3. The outdoor section of claim 2, wherein said first edge includes
a plurality of protrusions that engage said mating edge to tighten
said vertically sliding fit.
4. The outdoor section of claim 3 wherein at least one of said
plurality of protrusions extends from said first edge in a first
direction and at least one of said plurality of protrusions extends
from said first edge in a direction opposite said first
direction.
5. The outdoor section of claim 2 wherein said mating edge includes
a plurality of protrusions that engage said first edge to tighten
said vertically sliding fit.
6. The outdoor section of claim 5 wherein at least one of said
plurality of protrusions extends from said mating edge in a first
direction and at least one of said plurality of protrusions extends
from said mating edge in a direction opposite said first
direction.
7. The outdoor section of claim 2 wherein the first edge includes a
plurality of protrusions and has a first and a second leg and
wherein said mating edge is formed to capture said protrusions and
both said first leg and said second leg so as to prevent horizontal
movement of said first edge with respect to said within mating
edge.
8. The outdoor section of claim 1 wherein said at least one side
panel defines an opening that receives a catch protruding from the
base.
9. The outdoor section of claim 8 wherein said first side panel
defines a notch that receives an alignment tab extending from the
base.
10. The outdoor section of claim 1 wherein the first corner panel
defines an opening that receives a catch protruding from the
base.
11. The outdoor section according to claim 1 wherein said base is
fabricated from an engineered material and further comprising a
radio frequency identification device, said radio frequency
identification device being molded into said base.
12. The outdoor section according to claim 11 wherein said radio
frequency identification device is self-powered and transmits
predetermined information relating to said outdoor section.
13. The outdoor section for an air conditioner of claim 1 wherein
said base includes at least one breakaway shipping tab extending
integrally therefrom and further comprising a shipping pallet, said
at least one tab being attached to said pallet so that the severing
of said breakaway shipping tab from said base facilitates the
removal of said outdoor section from said shipping pallet.
14. The outdoor section for an air conditioner of claim 1 wherein
said heat exchanger coil includes adjacent tube rows and further
comprising a spacer, said spacer including an anchor and a head,
said anchor being ensconced between said tube rows and said head
juxtaposed one of said side panels so as to maintain a
predetermined distance between said side panel and said coil.
15. The outdoor section for an air conditioner of claim 14 wherein
the spacer is a unitary plastic piece.
16. The outdoor section of claim 1 further comprising an orifice
member, said orifice member defining an orifice and being supported
by said wrapper; a frame, said frame being fastened to said orifice
member; a fan motor, said fan motor being fastened to said frame
and said frame underlying and supporting said top cover; and, a
fan, said fan being driven by said fan motor and being positioned
in said orifice to draw air through said orifice and to discharge
air drawn through said orifice through said at least one opening in
said top cover.
17. The outdoor section according to claim 1 wherein at least one
of said plurality of side panels and one of said plurality of
corner panels cooperate in the formation of a pinless hinge, said
at least one of said plurality of said side panels and said at
least one of said plurality of corner panels which cooperate in the
formation of said pinless hinge being other than said one of said
plurality of side panels and one of said plurality of corner panels
that are engaged in said vertically sliding fit, said at least on
of said side panels that cooperates in the formation of said
pinless hinge having an edge which includes a first leg and a
second leg formed in an L-shape, and wherein said corner panel
which cooperates in the formation of said pinless hinge has a
mating edge, said mating edge capturing said L-shaped edge of said
side panel in a manner which permits said side panel to swing
outwardly and be removed from said wrapper so as to open the
interior of said wrapper for access.
18. The outdoor section according to claim 1 wherein said base
includes a surface, a resilient tab, a cleat and a post, at least
one of said corner panels defining a slot and being secured to said
base in a manner such that said cleat restrains horizontal movement
of said corner panel across said surface of said base in a first
direction, said tab restricts movement of said corner panel across
said surface of said base in a second horizontal direction and said
post prevents the vertical separation of said corner panel from
said base and protrudes through said slot defined by said corner
panel.
19. An outdoor section for an air conditioner, comprising: a base,
said base being fabricated from an engineered material and having
an integral peripheral rim extending upward therefrom and at least
one integral lead-in which extends upward therefrom, said lead-in
including a guide surface, said lead-in, said peripheral rim and
the base comprising a unitary piece; a heat exchanger coil having a
lower surface which rests on said base; and a side panel having a
lower edge, said side panel being connected to said base and being
interposed between said heat exchanger coil and said peripheral
rim, said guide surface of said lead-in guiding at least one of
said lower surface and said lower edge into a predetermined
position with respect to said base during assembly of said outdoor
section.
20. The outdoor section for an air conditioner of claim 19, wherein
said base includes an integral coil ramp upon which said lower
surface of said coil rests and wherein said lead-in is a coil
lead-in, said guide surface of said coil lead-in extending above
the lower surface of the heat exchanger coil when said coil rests
on said base.
21. The outdoor section for an air conditioner of claim 19, wherein
said lead-in is a wrapper lead-in, said guide surface of said
wrapper lead-in extending above the lower edge of the side panel
when said side panel is connected to said base.
22. The outdoor section for an air conditioner of claim 21, wherein
said base includes a catch juxtaposed said wrapper lead-in and said
side panel defines an opening, said catch protruding into said
opening defined by the side panel so as to hold said side panel in
place on said base and wherein said base includes an integral
alignment tab extending upward therefrom and said side panel
defines a slot, said alignment tab engaging said slot and
cooperating with said wrapper lead-in and said catch to position
and hold said side panel in a predetermined position on said
base.
23. The outdoor section for an air conditioner of claim 19 wherein
said base includes a radio frequency identification device, said
device being molded into said base.
24. An outdoor section for an air conditioner, comprising: a base;
a plurality of side panels connected to the base; a heat exchanger
coil supported by said base and disposed in said wrapper; a
plurality of corner panels, said plurality of side panels and said
plurality of corner panels cooperating to form a wrapper, at least
two of said corner panels and at least two of said plurality of
said side panels having vertically running edges that are secured
to each other in a vertical sliding relationship; an orifice member
supported by said wrapper, said orifice member defining a fan
orifice; a frame connected to and supported by said orifice member;
a fan; a fan motor fastened to said frame and to said fan, said fan
being positioned to draw air through said wrapper, said coil and
said fan orifice; and a top cover, said top cover having a
plurality of openings and being disposed above and supported by
said frame, air flowing out of aid orifice, past said frame and out
of said openings when said fan is in operation.
25. The outdoor section for an air conditioner of claim 24, wherein
the top cover is further supported by and engages the orifice
member.
26. An outdoor section for an air conditioner, comprising: a base;
a plurality of sheet metal panels connected to the base to define a
cabinet, said cabinet having an interior and an exterior, at least
one panel of the plurality of panels defining a dimple adapted to
receive a threaded fastener, said at least one panel cooperating in
the definition of a closed housing for electrical components and
separating the interior of the cabinet from said housing for
electrical components.
27. The outdoor section according to claim 26 wherein said at least
one panel defines a plurality of dimples protruding toward the
interior of said cabinet, at least one of said dimples being
penetrated by a threaded fastener and at least one of said dimples
being closed.
28. A method of assembling a cabinet for an outdoor section for an
air conditioner, wherein the cabinet include a base, a first side
panel, a second side panel, a third side panel, a first corner
panel, a second corner panel, a third corner panel, and a fourth
corner panel, the method comprising the following steps: installing
said first corner panel on said base; installing said second corner
panel on said base; and sliding said first side panel vertically
downward into engagement with said base and with both said first
corner panel and said second corner panel.
29. The method of claim 28 further comprising the further step of
installing said third corner panel on the base.
30. The method of claim 29 further comprising the further step of
sliding said second side panel vertically downward into engagement
with said base and with both said second corner panel and said
third corner panel.
31. The method of claim 30 further comprising the further step of
installing said fourth corner panel on the base.
32. The method of claim 31, further comprising the further step of
sliding said third side panel vertically downward into engagement
with said base and with both said third corner panel and said
fourth corner panel.
33. The method of claim 32 further comprising the further step of
swingably engaging and said fourth side panel with said first
corner panel and then securing said fourth side panel to said
fourth corner panel.
34. The method of claim 32 further comprising the further step of
sliding the fourth side panel vertically downward into engagement
with said base and with both said first corner panel and said
fourth corner panel.
35. The method of claim 28 wherein said step of installing said
first corner panel includes the step of slipping an opening in the
first corner panel around a catch protruding from the base.
36. The method of claim 35 further comprising slipping an opening
in the first side panel around a catch protruding from the
base.
37. The method of claim 36 wherein the first side panel defines a
notch and the base includes an alignment tab, and further
comprising the step of sliding the notch onto the alignment tab.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention pertains to a cabinet for an outdoor
section of an air conditioner, and more specifically to a cabinet
with features that facilitate its manufacturing and assembly.
[0003] 2. Description of Related Art
[0004] Air conditioners, including heat pumps, often include an
indoor section with an indoor heat exchanger for cooling or heating
the interior of a building and an outdoor section with an outdoor
heat exchanger for exchanging heat with the outside air. The two
heat exchangers are part of closed loop refrigerant circuit that
also includes a compressor and an expansion device, which compress
and expand the refrigerant respectively. As the refrigerant moves
through the circuit, its direction of flow determines whether the
indoor heat exchanger cools or heats the air inside the
building.
[0005] A typical outdoor section of an air conditioner includes a
cabinet that supports and shelters numerous components, such as the
compressor, various electrical components, the outdoor heat
exchanger, and a fan for drawing outside air through the heat
exchanger. The compressor relies on the base of the cabinet for
structural support; the electrical components need to be sheltered
from rain and snow; and the fan and heat exchanger need structural
support, exposure to outside air, and protection from the weather
and physical impact. Moreover, the cabinet should be readily
manufacturable and provide convenient access to any components
requiring service or repair. Providing a cabinet that effectively
serves all these needs without compromise can be challenging.
Nonetheless, many efforts to provide such a cabinet have been made
with some success.
[0006] For example, U.S. Pat. No. 5,294,195 discloses an outdoor
cabinet that houses electrical components at the top of the
cabinet. A small cover can be opened or removed for providing ready
access to the electrical components underneath. However, the edges
of the cover, being exposed along the top of the cabinet, create a
generally unsheltered seam that may leak or may be difficult to
seal against rain and snow.
[0007] Another cabinet for an outdoor section of an air conditioner
places its electrical components in a compartment underneath the
cabinet's top cover, as disclosed in U.S. Pat. No. 4,153,310. To
accommodate various models of air conditioners, the compartment has
numerous fastener and passage openings for installing various
combinations of components. However, having some openings left open
for some models may allow moisture to leak into the compartment
from other areas of the cabinet that may be more exposed to outside
air.
[0008] Some cabinets include features that enhance various
functions of the cabinet's base. For example, U.S. Pat. No.
4,471,633 discloses a non-corrosive plastic base with integrally
formed mounting pads that can support various size compressors and
other components. It also includes means for handling condensate.
Other cabinet bases that include special features for draining
condensate are disclosed in U.S. Pat. Nos. 4,748,827 and 4,748,828.
In U.S. Pat. No. 5,306,121, a cabinet base is shown having a novel
means for mounting the compressor. An intermediate plate between
the compressor and the base includes elastic isolators both above
and below the plate to avoid transmitting compressor vibration to
the base.
[0009] Another outdoor cabinet, disclosed in U.S. Pat. No.
6,168,248, discloses a plastic base with positioning cleats that
help align the side panels, or sheet metal wrapper, to the base.
Once in position, a series of screws fasten the side panels to the
side of the base. Each of the outer side panels has an L-shape to
extend the length of two sides of the base. L-shape panels may
simplify assembly; however, later servicing may be more difficult,
as technicians may have to fully uncover two sides of the outdoor
cabinet even in situations where access to only side is needed.
Moreover, many of screws for fastening the wrapper to the base are
along the lower edge of the cabinet. Such a location may be awkward
to reach once the cabinet is installed outside at generally ground
level.
SUMMARY OF THE INVENTION
[0010] To facilitate the assembly and later servicing of an air
conditioner's outdoor section, it is an object of the invention to
provide a cabinet that can be assembled with a minimal number of
fasteners.
[0011] Another object is to provide a cabinet whose base includes
snap-in elements that help hold the cabinet's wrapper to the
base.
[0012] Another object is to provide a base with a raised peripheral
rim that helps hold the cabinet's wrapper in position.
[0013] Yet, another object is to provide the base with wrapper
lead-ins that help properly position the wrapper against the raised
peripheral rim.
[0014] A further object is to provide a cabinet's base with
upwardly protruding lead-ins that help guide a heat exchanger coil
into position as the coil is being lowered onto the base.
[0015] A still further object is to provide a cabinet wrapper with
side panels that interlock by way of a sliding connection between
adjacent panel members.
[0016] A still further object is to provide side or corner panels
with a series of dimples that enhance the holding power of the
sliding connection between adjoining panel members.
[0017] Another object is to provide an assembly sequence for the
cabinet such that each panel member helps hold its adjacent panel
members in place, yet the panel members can be installed and
removed individually.
[0018] Another object is to provide certain panel members of a
cabinet with screw-receiving dimples at various locations. Each
dimple can serve as a pilot hole for inserting a screw for mounting
various electrical components. The dimples are watertight, so if
any are left unused, they can inhibit water from entering the area
where the electrical components are installed.
[0019] Another object of the invention is to provide an air
conditioner cabinet with a spacer that helps hold the cabinet's
wrapper spaced apart from a heat exchanger coil contained inside
the cabinet.
[0020] Yet another object is to provide such a spacer with an
anchor that allows the spacer to hold itself to the coil of a heat
exchanger. The anchor may allow infinite repositioning of the
spacer.
[0021] Another object is to provide an air conditioning cabinet
with a fan frame that not only supports the frame, but also helps
support the cabinet's top cover.
[0022] Another object is to provide the base of an air conditioner
cabinet with breakaway shipping tabs. When shipping the unit, the
tabs help hold the cabinet to a shipping pallet. Later, the tabs
can be severed to readily remove the cabinet from the pallet.
[0023] These and other objects of the invention are provided by an
outdoor section of an air conditioner that includes a wrapper
mounted to a plastic base. To facilitate the assembly or servicing
of the air conditioner, the base may include one or more features
such as wrapper or coil lead-ins, a raised peripheral rim to hold
the wrapper, snaps rather than screws to anchor the wrapper to the
base, and breakaway shipping tabs. The wrapper may also include one
or more features such as interconnecting sliding seams; watertight
dimples for receiving screws; or a sequence of assembly that allows
the wrapper's panels to support each other, yet allows the panels
to be installed and removed individually.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a cutaway front view of an outdoor section of an
air conditioner according to one embodiment of the invention.
[0025] FIG. 2 is a top view of the outdoor section of FIG. 1, but
with an upper portion and one shipping tab removed.
[0026] FIG. 3 is a cross-sectional view taken along line 3-3 of
FIG. 2.
[0027] FIG. 4 is a cross-sectional view taken along line 4-4 of
FIG. 2.
[0028] FIG. 5 is a cross-sectional view taken along line 5-5 of
FIG. 2.
[0029] FIG. 6A is a cross-sectional view taken along 6A-6A of FIG.
5.
[0030] FIG. 6B is similar to FIG. 6A but of an other
embodiment.
[0031] FIG. 7 is a top view of a side panel and a corner panel.
[0032] FIG. 8 is a cross-sectional view taken along line 8-8 of
FIG. 7.
[0033] FIG. 9 is a top view of a wrapper/coil spacer.
[0034] FIG. 10 is a front view of the spacer of FIG. 9.
[0035] FIGS. 11-18 show one possible assembly sequence of the
wrapper as viewed from the top.
[0036] FIG. 19 is a front view of a side panel being slid downward
into position between two corner panels.
[0037] FIG. 20 is a top view of a fan, fan frame, and a fan orifice
member.
[0038] FIG. 21 is a cross-sectional top view showing how a
watertight dimple is formed and how a screw is subsequently
installed through it.
[0039] FIG. 22 is a front view of an outdoor section being removed
from a shipping pallet.
[0040] FIG. 23 is a perspective view of control box corner panel
latching arrangement in the outdoor suction of the present
invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0041] FIG. 1 is a cutaway view showing the basic components of an
outdoor section 10 of an air conditioner. The term, "air
conditioner" refers to any apparatus (including, but not limited to
heat pumps) for cooling and/or heating a comfort zone, such as a
room or area within a building. In this case, outdoor section 10
includes a cabinet 12 containing a refrigerant compressor 14, an
outdoor heat exchanger coil 16, and a fan 18. Through lines 20 and
22, a conventional closed loop refrigerant circuit connects
compressor 14 and outdoor coil 16 to the air conditioner's indoor
section, not shown, which may include an indoor heat exchanger coil
associated with a blower for delivering cooled or heated air to the
comfort zone. Whether the indoor coil is used for heating or
cooling depends on the configuration of the particular refrigerant
circuit, and more specifically, the sequence through which the
refrigerant flows through the indoor coil, outdoor coil 16,
compressor 14, and an expansion device (e.g., an expansion valve,
capillary tube, or similar flow restrictor).
[0042] The primary focus of the invention pertains to cabinet 12 of
outdoor section 10. Referring to FIGS. 1 and 2, cabinet 12 includes
a base 24 and a wrapper 26. Base 24 is preferably fabricated from
an engineered material such as polypropylene, ABS or polycarbonate.
Wrapper 26 comprises several interconnected sheet metal panels,
such as side panels 28, 30, 32 and 34 and corner panels 36, 38, 40
and 42. Wrapper 26 and base 24 include numerous features that
facilitate the cabinet's assembly, enhance its appearance, and
ensure its structural and functional integrity.
[0043] For example, referring to FIGS. 1-3, base 24 includes
several coil lead-ins 44 that each has an inclined surface 46 for
guiding a lower surface 48 of coil 16 into its proper position on
coil ramp 49 of base 24 during assembly. Lead-ins 44 extend
integrally from base 24, such that base 24 and lead-ins 44 comprise
a unitary piece for ease of manufacturing.
[0044] Referring further to FIG. 4, coil 16 is preferably a
helically wound coil. Lower surface 48 of coil 16 sits on a helical
coil ramp 49 that rises off of base 24 and is preferably integral
therewith. In that regard, first end 49a of coil ramp 49 is
essentially flush with the surface of base 24 and helically
increases in height in a direction toward end 49b of the coil ramp.
The helical ramping of coil ramp 49 accommodates the helical wind
of coil 16 with the result that coil 16 is stable and sits
vertically on base 24.
[0045] Base 24 also includes several wrapper lead-ins 50 that each
has an curved surface 52 for guiding a lower edge 54 of wrapper 26
into its proper position on base 24 and up against or at least
adjacent to a raised peripheral rim 56. Wrapper lead-ins 50 are
also integrally formed with base 24 to comprise a unitary
piece.
[0046] Several alignment tabs 58 provide further alignment of
wrapper 26 to base 24, as shown in FIGS. 2 and 5. Each alignment
tab 58 extends integrally from base 24 and is adapted to engage a
slot 60 in a side panel of wrapper 26. Thus, lead-ins 50, alignment
tabs 58, and rim 56 all help to ensure that the side panels and the
totality of wrapper 26 are installed in their proper position and
relationship relative to base 24.
[0047] To reduce the use of conventional threaded fasteners, a
number of catches 62 integrally extending from peripheral rim 56 of
base 24 help secure wrapper 26 in place, as shown in FIGS. 2, 5 and
6A. Each catch 62 protrudes into a hole 64 of a side plate of
wrapper 26. A lower edge 66 of catch 62 engages the lower edge of
hole 64, which limits the extent to which wrapper 26 can move away
from base 24 once the wrapper is in place. Providing catch 62 with
a tapered upper edge 68 and staggering the positions of catches 62
relative to lead-ins 50 (i.e., the catches and lead-ins are not
directly across from each other) allows wrapper 26 to flex and snap
into place by lowering wrapper 26 between catch 62 and lead-ins 50
during assembly.
[0048] This snap-in feature is further illustrated in the
embodiment of FIG. 6B, wherein a lead-in 50' replaces lead-in 50
and is positioned closer to rim 56 to ensure more positive
engagement between catch 62 and wrapper 26. Staggering the
positions of catches 62 and lead-ins 50' allows the positioning of
the catches and lead-ins such that a greater spacing 70 exists
between peripheral rim 56 and a distal edge 72 of catch 50' than a
spacing 74 between rim 56 and a shoulder 76 of leadin 50'. Yet, the
wrapper's flexibility still allows wrapper 26 to snap into
position.
[0049] To hold corner panels 36, 38 and 40 in place, another catch
78 extending from rim 24 protrudes through a hole 80 in those
corner panels, as shown in FIGS. 2 and 3. Side panel 28 and corner
panel 42 are each somewhat unique as will further be described
below.
[0050] In a currently preferred embodiment, catch 78 protrudes much
farther from rim 24 than does catch 62 and includes an upper
surface that has a vertically extending lip 83. At assembly, the
hole 80 of each of these corner panels is engaged over a
corresponding catch 78 and is rotated to the vertical position
illustrated in FIG. 3. Once the remainder of wrapper 26 is
assembled, the substantial protrusion of catches 78 provides a very
positive, solid connection between base 24 and the corner panels.
However, in the rare event that it becomes necessary to remove a
side panel to corner piece after assembly, such removal can be
accomplished by the simple expedient of disengaging the catches 62
and/or 78 from the hole in the wrapper or corner panel in which
they reside.
[0051] To hold the sides of wrapper 26 together with a minimal
number of screws (if any), the wrapper's various side and corner
panels are interconnected by vertically sliding fits between mating
edges of adjacent panels. Referring to FIGS. 2 and 7, for example,
the vertical edges of side panel 30, like those of side panels 32
and 34, are roll formed (or otherwise formed) to create two
generally L-shaped edges 84 and 86. One or more corner panels also
have their vertical edges roll formed (or otherwise formed) to
create edges adapted to receive the L-shaped edges of an adjoining
wrapper panel. Corner panel 36, for example, includes edges 88 and
90. Mating edge 88 of corner panel 36 engages edge 86 of side panel
30 to create a vertically sliding fit 92, referred to as a slip
seam, between the two.
[0052] To inhibit side panel 30 from horizontally separating from
corner panel 36, edge 88 is formed to wrap at least partially
around and capture the L-shaped edge 86 of side panel 30, as is the
case with side panels 32 and 34 and their interaction with the
corner panels between which they reside. More specifically, edge 88
includes a first segment 94 and a second segment 96 that restrains
and limits the movement of edge 86 of side panel 30 in a first
horizontal direction. Further, edge 88 includes a third segment 98
and a fourth segment 100 that restrains and limits the movement of
edge 86 of side panel 30 in a second horizontal direction generally
perpendicular to the first direction.
[0053] Referring to FIGS. 7 and 8, forming a series of dimples 102
along vertical edge 84 or 86 of a side panel such as side panel 30
creates a corresponding series of protrusions 104 that enhance the
vertical grip between the side panels and corner panels of wrapper
26. Protrusions 104 are spaced apart and face in opposite
directions, so that as edge 86 is slid vertically downward within
the confines of edge 88 of a corner panel, the inner surfaces of
edge 88 engage dimples 104 and then urge into a more coplanar
orientation, which causes resilient localized bending in the sheet
metal of edge 86. The resilience of the sheet metal acting upon
protrusions 104 maintains horizontal pressure between protrusions
104 and the inner surfaces of edge 88. The horizontal pressure
creates a frictional force that tightens the sliding fit between
edges 86 and 88 and results in a strong and rigid unit wrapper
26.
[0054] In assembling outdoor section 10, compressor 14 and coil 16
are generally the first main components to be installed on base 24.
In some cases, one or more plastic spacers 106, such as the one
shown in FIGS. 1, 2, 9 and 10 can be attached to coil 16 to ensure
adequate space for airflow between coil 16 and the adjacent wrapper
26 and, when outdoor section 10 is part of a heat pump system, to
inhibit frost/ice bridging between the wrapper and coil. Also, if
coil 16 includes spine fins 108, ensuring such space between coil
16 and wrapper 26 may help prevent wrapper 26 from crushing the
fins either during or after assembling the unit.
[0055] In a currently preferred embodiment, spacer 106 comprises a
unitary plastic injection molded piece having a head 110 and an
anchor 112 at opposite ends. Head 110 is adapted to abut an inner
face of a side panel, and anchor 112 engages coil 16. In some
embodiments, spacer 106 attaches to coil 16 by forcing anchor 112
between the spine fins 108 of two adjacent coil wraps or tube
sections 114 and 116 of coil 16. Anchor 112 firmly engages the
spine fins 108 of tube sections 114 and 116 and thereby holds
spacer 106 in place. Head 110 preferably includes a tapered surface
118 that can help redirect a lower edge of a side panel away from
coil 16 as the panel is being lowered into position during
assembly.
[0056] Assembling the side and corner panels to base 24 preferably
follows the suggested steps illustrated sequentially in FIGS.
11-19. In FIG. 11, corner panel 36 is installed with hole 80 being
slipped around catch 78 in a manner previously explained with
reference to FIGS. 2 and 3. In a similar manner, corner panel 38 is
installed next, as shown in FIG. 12. Next, side panel 30 is
vertically slid downward into position between corner panels 36 and
38, as shown in FIG. 13, having been piloted into final position on
base 24 by lead-ins 50 and alignment tabs 58 as earlier described.
At this point in the assembly process, side panel 30 and corner
panels 36 and 38 are generally well supported. The vertical edges
of side panel 30 are fully engaged in the mating edges of corner
panels 36 and 38, catch 62 has side panel 30 snapped into position
between rim 56 and lead-in 50, and the lower ends of corner panels
36 and 38 engage their respective catches 78.
[0057] Assembly may continue by installing corner panel 40, as
shown in FIG. 14, and then sliding side panel 32 between corner
panels 38 and 40, as shown in FIG. 15. Next, in FIG. 16, corner
panel 42 is installed on the base. Because of its unique geometry
and function, corner panel 42 latches into base 24 in a manner
different from the other corner panels and has a unique seam 42a
that is best illustrated in FIG. 21 which is discussed below.
[0058] Next, side panel 34 is slid into position between corner
panels 40 and 42, as illustrated in FIG. 17, and side panel 28 is
engaged between corner panels 36 and 42, as shown in FIG. 18 and as
will subsequently be described. FIG. 19 shows a front view of how a
side panel (e.g., side panel 32) is slid into position between two
supporting corner panels (e.g., corner panels 38 and 40).
[0059] Once base 24 and wrapper 26 are assembled to the extent
shown in FIGS. 2 and 18, an orifice member 120 can be installed on
top of wrapper 26, as shown in FIGS. 1 and 20. Orifice member 120
defines a fan orifice 122. In operation, fan 18 draws outside air
through louvers 124 in the side panels of wrapper 26 and across
coil 16 so as to exchange heat with the refrigerant inside the
coil.
[0060] Fan 18 is driven by a motor 126 that is supported by a frame
128 attached to orifice member 120. Frame 128 comprises two
substantially identical sheet metal frame members 130 that can be
attached to each other in a conventional manner, such as by way of
screws, welding, etc. Together, frame members 130 provide four tabs
132 that are screwed or otherwise attached to motor 126 to support
and position motor 126 within orifice member 120 and four other
tabs 134 that attach to orifice member 120 so as to secure frame
128 thereto. Each frame member 130 includes two flange surfaces 134
and 136 for stiffness and for providing a surface area upon which a
top cover 138 rests and finds support.
[0061] Top cover 138 rests atop frame 128 and provides a protective
shield over fan 18. As fan 18 draws outside air into cabinet 12 and
across coil 16, openings 140 around the perimeter of cover 138
allow fan 18 to discharge the air back to the ambient, generally in
a direction which is upward and away from the cabinet sides. A
lower rim 142 of cover 138 attaches to wrapper 26 by way of screws
or some other appropriate means for attachment. In some cases, an
outer rim 144 of orifice member 120 lies between cover rim 142 and
the upper edge of wrapper 26, so top cover 138 engages orifice
member 120.
[0062] Since outside air is drawn into cabinet 12, moisture can be
drawn in as well. To prevent that moisture from contaminating
electrical components 146 associated with air conditioner 10,
components 146 are housed inside a compartment 148 adjacent corner
panel 42 and underneath top cover 138, as shown in FIGS. 1, 2 and
21. Components 146 are schematically illustrated to represent any
type of electrical component including, but not limited to, relays,
motor starters, motor starting capacitor, wires, control circuits,
electrical terminals, etc. Corner panel 42 shelters the electrical
components 146 from moisture that may be inside cabinet 12, while
an outer access panel 150 fastened to corner panel 42 provides
shelter from air outside of cabinet 12. Thus, in this example,
corner panel 42 serves as an "interior panel," whereby panel 42 is
exposed to an interior 152 of cabinet 12 and is at least partially
sheltered from an exterior 154 of cabinet 12 (see FIG. 2).
[0063] Referring to FIGS. 2 and 21, components 146 can be mounted
inside compartment 148 by various means. For example, components 16
may be readily attached using a screw 156 or some other type of
fastener (e.g., a self-tapping screw, sheet metal screw, rivet
etc.). In a currently preferred embodiment, corner panel 42 is
provided with closed screw-receiving dimples 154 at numerous
preplanned locations to accommodate various component-mounting
arrangements for various air conditioner models. Depending on the
model of a particular unit, some dimples 154 may receive a screw
156 and others may be left unused. If left unused, dimple 154
remains watertight to help prevent moisture inside cabinet 12 from
leaking into compartment 148.
[0064] Dimples 154 are created by a conventional forming tool 158,
as shown in FIG. 21. Dimples 154 are sufficiently deep and narrow,
so that as screw 156 is turned into dimple 154, the threads of the
screw bite into and grip the inner walls of the dimple, as
indicated by screw 156'. Further tightening of the screw forces the
screw to break through the bottom of the dimple, as indicated by
screw 156". To hold the screw in place, a nut may be installed on
the screw, or the thread marks left on the inner wall of the now
open dimple may be sufficient to hold the screw.
[0065] Still referring to FIGS. 2 and 21 but additionally to FIG.
18, side panel 28 has a first vertical edge 28a which is configured
in the same manner as the vertical edges of side panels 30, 32 and
34. The other vertical edge 28b of side panel 28 is configured
differently and has a lip 28c that becomes ensconced in the
vertically running opening at end 42a of corner panel 42 when panel
28 is assembled to the remainder of the wrapper.
[0066] Referring primarily now to FIG. 18, on assembly of side
panel 28 to the remainder of the wrapper 26, vertical edge 28a of
side panel 28 is inserted into the accommodating vertically running
opening in edge 36a of corner panel 36. Such engagement results in
the creation of what is essentially a pinless hinge. In that
regard, once edge 28a of panel 28 is engaged within accommodating
vertically running opening at the edge 36a of corner panel 36,
panel 28 is swung inward, in the direction indicated by the arrow
28c in FIG. 18, until lip 28d of panel 28 enters the vertically
running opening in end 42a of corner panel 42. Edge 28b of side
panel 28 is then secured to end 42a of corner panel 42 using one or
more fasteners, such as sheet metal screw 159.
[0067] Referring primarily now to FIG. 2, because of the unique
arrangement and function of side panel 28, base 24 is somewhat
modified on the side of it which supports panel 28. In that regard,
the lower edge of panel 28 rests on supports 24a which are integral
with and extend inwardly from rim 56 of base 24 at a horizontal
height coincident with the height of the upper edge of rim 56.
Supports 24a therefore support side panel 28 on base 26 while at
the same time accommodating the ability of panel 28 to swing
outward without interference from base 24. Panel 28 is therefore
easily removed and access to the interior of wrapper 26 is thereby
gained. Because supports 24a are employed in support of panel 28,
alignment tabs 58 and catches 62 are dispensed with on this side of
base 24.
[0068] Referring now to FIG. 22, temporarily mounting the outdoor
section to a conventional shipping pallet 160 may help in
transporting the unit before the outdoor section is permanently
installed at its installation site. To that end, one or more
breakaway shipping tabs 162 extend integrally from the perimeter of
base 24, while a fastener 164 anchors tabs 162 to pallet 160.
Fastener 164 is schematically illustrated to represent any type of
conventional fastener including, but not limited to, a staple,
nail, screw, etc. To remove the outdoor section from pallet 160,
tabs 162 are severed by cutting, tearing, prying, or breaking,
which releases base 24 and leaves a now scrap portion 162' of tab
160 still attached to pallet 160. Alternatively, the staple, nail
or screw holding the unit to the pallet can itself be removed
leaving the tabs intact. If so, the tabs can be used to secure the
unit to the surface on which it is ultimately installed.
[0069] Also to be noted with respect to FIG. 22, it is contemplated
that a radio frequency identification device may be embedded/molded
into base pan 24. Device 166 is a relatively inexpensive device
capable of transmitting information relating to the specific
outdoor section 10 in which device 166 is embedded. Such
information might include the serial number of the unit, model,
information relating to the refrigerant it is charged with, date of
manufacture and other such information that may be useful with
regard to servicing the unit.
[0070] Because device 166 will have been molded into/embedded in
base pan 24 prior to the assembly of outdoor section 10 in the
factory and because outdoor sections 10 are, generally speaking,
built from the base pan up, device 166 can contain additional
information that is likewise readable by receiving devices
positioned on the assembly line within the factory. As such, device
168 in FIG. 22 is representative of both a service device used in
the field and a device that might be mounted on the assembly line
in the factory where outdoor section 10 is manufactured.
[0071] Information used in the manufacturing process within a
factory might include model number-related information that would
be read as the base pan moves down the assembly line. Such
model-related information can be used to trigger the display of
information or instruction to assemblers with regard to the model
being configured and the particular components/pieces that are to
be used in assembling that particular model. As will be
appreciated, such information might also be of value and be used in
the context of warehousing, shipping and distribution of outdoor
units. Overall, by the use of a relatively inexpensive and
long-lived radio frequency transmitting device embedded in base pan
24, which may be self-powered and triggered in response to a query
from device 168, a wealth of information is made available from the
start of assembly of individual outdoor section 10 to the service
of that outdoor section years later in the location in which it is
installed.
[0072] Referring now to FIG. 23, the control box corner panel to
base pan latching arrangement is illustrated. As has been noted,
corner panel 42 is of a unique geometry and function in that it
cooperates in the definition of the walls of compartment 148 in
which control components are housed. As has also been noted, corner
panel 42 latches into base 24 in a manner different from the other
corner panels of cabinet 12.
[0073] In that regard, in order to latch panel 42 to base pan 24,
panel 42 is aligned with the base pan such that surface 202 of
panel 42 is adjacent recessed surface 204 of cleat 206 on base pan
24. In that position, notch 208 of surface 202 rests over
horizontal surface 210 of cleat 206. At the time such alignment is
made, post 212 of base pan 24 is generally in alignment with but
does not protrude through slot 214, which is defined in surface 202
of corner panel 42, at end 216 thereof.
[0074] With corner panel 42 SO aligned, panel 42 is moved
horizontally away from surface 204 of cleat 206 in the direction
indicated by arrow 218. As corner panel 42 is so moved, notch 208
moves off of cleat 206 and post 212 penetrates slot 214 and
protrudes therethrough at end 216 thereof. This position is
generally illustrated by the phantom lines in FIG. 23.
[0075] Panel 42 is then moved horizontally in the direction
indicated by arrow 220, such direction being at a 900 angle to the
direction indicated by arrow 218. In the process of moving panel 42
in the second horizontal direction, indicated by arrow 220, post
212 slides within slot 214 and comes into abutment with end 222 of
slot 214. End 222 of the slot therefore limits the horizontal
movement of corner panel 42 in the direction indicated by arrow
220.
[0076] At the same time and because the lower edge of surface 224
of corner panel 42 will have originally been positioned over
surface 226 of resilient tab 228 on base pan 24, surface 224 will
have depressed resilient tab 228 in the process of moving in the
direction of arrow 220 and will have moved just past the end 230 of
tab 228 when post 212 comes into abutment with end 222 of slot 214.
Once the lower edge of surface 224 moves past end 230 of resilient
tab 228, tab 228 springs upwardly to effectively and securely latch
corner panel 42 in position on the base pan.
[0077] It is to be noted that one or more others of cleats 206,
notches 208, slots 214 and posts 212 may exist on or in base pan 24
and corner panel 42 and be similarly arranged with respect to
surface 202 of the corner panel. It is further to be noted that
base pan 24 may include other cleats, posts and alignment tabs.
These include post 232 which comes to protrude through slot 34 of
surface 224 of corner panel 42 as the corner panel moves in the
direction of arrow 220. Cleat 236 similarly positions, abuts and
secures surface 238 control panel 42 into position on base pan 24
both in the initial assembly process and once corner panel 42 is
latched into place.
[0078] Although the invention is described with reference to a
preferred embodiment, it will be appreciated by those skilled in
the art that other variations are well within the scope of the
invention. For example, vertically sliding fits, such as fit 92,
can be applied to any number of adjoining wrapper panels. In some
embodiments of the invention, all the wrapper panels are joined in
this manner, as shown in FIG. 2. In other embodiments, some wrapper
panels are connected by a vertically sliding fit, and others are
connected by screws in a more conventional manner. It should be
appreciated by those skilled in the art, that alternatively, the
L-shaped edge could be on corner panel 36 and the edges of side
panel 30 could be similar to edge 88. It should also be
appreciated, that wrapper 26 could have more or less than the eight
panels shown in the drawing figures. For example, it would be well
within the scope of the invention to provide a wrapper with just
four side panels that interconnect directly with each other without
intervening corner panels. Therefore, the scope of the invention is
to be determined by reference to the claims, which follow.
[0079] We claim:
* * * * *